Synthetic molded slabs, and systems and methods related thereto

ABSTRACT

This document describes systems and processes for forming improved synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).

CROSS-REFERENCE TO RELATED APPLICATION(S)

This is a divisional of U.S. patent application Ser. No. 14/879,477,filed on Oct. 9, 2015, which is a divisional of U.S. patent applicationSer. No. 14/878,393, filed on Oct. 8, 2015, which is a continuation ofU.S. patent application Ser. No. 14/463,494 filed on Aug. 19, 2014, theentire contents of which are incorporated herein by reference.

TECHNICAL FIELD

This document describes systems and processes for forming synthetic moldslab products, for example, a synthetic mold slab that is thermoformedor otherwise compacted to a selected slab shape from a mixture includingparticulate mineral material, resin binder, and pigments so that thesynthetic molded slab is suitable for use in living or working spaces(e.g., along a countertop, table, floor, or the like).

BACKGROUND

Quarried stone slabs are a commonly used building material. Granite,marble, soapstone, and other quarried stones are often selected for useas countertops due to their aesthetic properties. Despite the visualappeal of quarried stone, such quarried stone slabs can be quiteexpensive to obtain and are generally limited to naturally occurringcolor schemes.

Engineered stone slabs may be formed from a man-made combination ofmaterials that can provide improved stain-resistant or heat-resistantproperties compared to quarried stone slabs. Engineered stone istypically a combination of particulate mineral material and a binder,such as a polymer resin or cement. Some engineered stone slabs,especially those of a larger slab size and having a granular formationappearance, can fall noticeably short of the complicated look andtexture of quarried stone slabs.

SUMMARY

Some embodiments described herein include systems or processes forforming improved synthetic molded slabs suitable for use in living orworking spaces (e.g., along a countertop, table, floor, or the like). Inparticular embodiments, the synthetic molded slabs can be manufacturedso as to have a similar appearance to one another that, unlike quarriedstone slabs taken from a quarry, is generally repeatable and predefinedas part of the manufacturing process. In those embodiments, however, theappearance of each synthetic molded slab can provide complex striationsor other veining patterns that emulate a quarried stone slab. Forexample, each slab can be formed from a combination of differentlypigmented particulate mineral mixes that are vertically dispensedaccording to predefined pattern into a vertically oriented mold (therebyfacilitating the selected striations or other veining patterns), whichis then shifted to a horizontally oriented position for subsequentcompression molding and curing operations. As used herein, “differentlypigmented” means having different pigment combinations or otherwisehaving a different visual appearance in color tone or visual texture.

Particular embodiments described herein include a synthetic molded slabcomprising a quartz material. Optionally, the synthetic molded slab mayhave a major surface at least 2 feet wide by at least 6 feet long andextending perpendicularly to a slab thickness. The major surface may atleast a first pigmented vein extending generally lengthwise fromedge-to-edge that separates at least two other veins extending generallylengthwise and positioned on opposing edges of the first pigmented vein.The first pigmented vein optionally has a vein thickness equal to andparallel to the slab thickness.

Some embodiments described herein include a set of separately moldedsynthetic slabs. Each respective slab of the set may include at leastfour different particulate mineral mixes distributed in the series ofsuccessive layers according to the predefined pattern for all of theseparately molded synthetic slabs. The four different particulatemineral mixes may each optionally comprise a quartz material, one ormore pigments, and one or more resin binders. In one preferred option,each respective slab may be rectangular and may have major surface witha width or at least 2 feet and a length of at least 6 feet. At least oneof the four different particulate mineral mixes may define substantiallylengthwise veins extending for a majority of the length of eachrespective slab such that the major surface of each respective slab inthe set has similarly positioned and colored substantially lengthwiseveins.

Other embodiments described herein include a process of forming asynthetic molded slab from different particulate mineral mixes. Theprocess may include positioning a slab mold in a substantially verticalorientation. The process may also include dispensing multiple differentparticulate mineral mixes into the substantially vertically orientedmold so as to fill a mold space. Optionally, the mold space is at least6 feet long by at least 2 feet wide, and the multiple differentparticulate mineral mixes each comprise predominantly a quartz material.The process may further include adjusting the mold to a substantiallyhorizontal orientation while the different particulate mineral mixes arepositioned in the mold. Also, the process may include contemporaneouslyvibrating and compacting the particulate mineral mixes arranged in themold while the mold is in the substantially horizontal orientation.

Some embodiments of a process of forming a synthetic molded slab includepouring multiple differently pigmented particulate quartz mixes into anon-horizontally oriented mold according to a predetermined pattern.Optionally, the non-horizontally orientated mold may define an internalspace having a first edge thickness that is smaller than and parallel toa second edge thickness proximate to an upwardly facing opening of themold. The process may also include compacting the multiple differentlypigmented particulate quartz mixes arranged in the mold while the moldis in the horizontal orientation.

Additional embodiments described herein include a system forming asynthetic molded slab using a combination of different particulatemineral mixes. The system may include a mold adjustment apparatusconfigured to reposition a slab mold from a substantially verticalorientation to a substantially horizontal orientation. Optionally, theslab mold may define a mold space that is at least 6 feet long by atleast 2 feet wide. The system may also include one or more mineralaggregate distributors that are each configured to dispense acorresponding particular mineral mix vertically into the slab moldretained by the mold adjustment apparatus.

The systems and techniques described herein may provide one or more ofthe following advantages. First, a system can be used to produce aplurality of synthetic molded slabs that each have similar vein patternsand that are suitable for use in living or working spaces (e.g., along acountertop, table, floor, or the like). Such slabs can be formed from acombination of differently pigmented particulate mineral mixes that arevertically deposited according to predefined and repeatable dispensationpattern into a vertically oriented mold, which provides the selectedveining patterns that emulate a quarried stone slab and that aregenerally repeatable for each slab in the plurality of separately moldedslabs.

Second, each slab in the system can be formed from a series operationsincluding at least a compression molding operation in which the moldcontaining the particulate mineral mixes are positioned in a horizontalorientation after the mold is filled in the vertical orientations. Forexample, the differently pigmented particulate mineral mixes arevertically poured into the vertically oriented mold, which is thenshifted to a horizontally oriented position for a subsequent compressionmolding operation (e.g., vibro-compaction molding, or the like) and (insome embodiments) a curing operation. From there, some or all of themold is removed from the hardened slab so that at least a major surfaceof the slab is polished to provide an appearance of the complexstriations and veining patterns that emulate a quarried stone slab. Insome optional embodiments, the polished major surface of each of thesynthetic molded slabs provides an outer appearance that is remarkablysimilar to the other slabs in the set of separately molded slabs, unlikequarried stone slabs taken from a quarry. Moreover, the pigments andparticulate mineral mixes can be selected to provide color combinationsand visual effects that improved upon and offer a variety of colorcombination options far beyond what is available from quarried stoneslabs taken from a quarry.

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other features andadvantages will be apparent from the description and drawings, and fromthe claims.

DESCRIPTION OF DRAWINGS

FIGS. 1A and 1B are perspective views of a synthetic molded slab duringand after formation, in accordance with some embodiments.

FIG. 2 is a diagram of an example system for forming a synthetic moldedslab product, in accordance with some embodiments.

FIG. 3 is a diagram of another example system for forming a syntheticmolded slab product, in accordance with other embodiments.

FIGS. 4A and 4B are perspective and cross-sectional views of a slab moldadjustment apparatus of FIGS. 2 and 3 in a horizontal configuration.

FIG. 5 is another cross-sectional view of the slab mold adjustmentapparatus of FIGS. 4A and 4B.

FIGS. 6A-6C are perspective and cross-sectional views of the slab moldadjustment apparatus of FIGS. 4A and 4B in a vertical configuration.

FIG. 7 is a perspective view of an example synthetic molded slab productformed by either of the systems of FIGS. 2 and 3.

FIG. 8 is a flow diagram of an example process for forming a syntheticmolded slab product.

DETAILED DESCRIPTION

Referring to FIGS. 1A and 1B, a system can be used to produce one ormore synthetic molded slabs 50 having a number of striations or veinsaccording to a predefined pattern. Each slab 50 can comprise a quartzmaterial and/or other particulate mineral material that, when mixed withpigments and a resin binder and subsequently compressed and cured,provides a hardened slab product suitable for use in living or workingspaces (e.g., along a countertop, table, floor, or the like). As shownin FIGS. 1A-B, each slab 50 may optionally be formed from a combinationof differently pigmented particulate mineral mixes that are verticallypoured according to predefined and repeatable dispensation pattern intoa vertically oriented mold 130 (refer to FIG. 2), which provides theselected striations or other veining patterns that are generallyrepeatable for each separately molded slab a slab mold is orientedvertically and filled from an open end. Successive layers of differentparticulate mineral mixes (e.g., different pigments, different mineralcompositions, different additives, or the like) are vertically pouredaccording to predefined and repeatable dispensation pattern into themold until filled. The open end is closed, and the mold 130 is pivotedto a horizontal orientation (refer to the apparatus 150 in FIGS. 2-3)and then transported in the horizontal orientation for compaction,curing, and other operations. As shown in FIG. 1B, depending upon thepredefined dispensation pattern of the different particular mixes, thevertical dispensation/layering process can provide a layering effectthat emulates the veined appearance of quarried stone slabs such asgranite or marble, including some veins 51, 52, 53, and 54 that extendfully across a complete length L of the hardened slab 50 (e.g., at least2 feet wide by at least 6 feet long, and between about 3 feet and 5 feetwide and between about 6 feet and 14 feet long, preferably about 4.5feet wide (more particularly, about 140 cm wide) by about 10 feet long(more particularly, about, 310 cm long)). Other veins 55 may extend onlypartially across the length L of the slab 50. Not only can suchdifferently pigmented veins 51, 52, 53, and 54 extend across the fulllength of the slab product, but such veins 51, 52, 53, and 54 (and alsopartial vein 55) can also extend through the thickness of the slab 50(thereby providing a natural vein appearance even when the slab is cutand edged to specific shapes in living or working spaces (e.g., along acountertop, table, floor, or the like). Because each slab 50 in the setof separately molded slabs can include the layers of differentparticulate mineral mixes dispensed vertically into the mold 130 (referto FIG. 2) according to the predefined and repeatable dispensationpattern, multiple slabs 50 in the set of separately molded slabs canhave substantially the same appearance to one another.

Referring now to FIGS. 1A-B and 2 in more detail, the mold 130 can bevertically oriented during the dispensation of the different particulatemineral mixes into the mold 130. For example, as described in moredetail below, the mold 130 can include a shell portion that at leastpartially defines a space (shown in dashed lines in FIG. 1A) forreceiving the different particulate mineral mixes via an open upwardlyfacing opening 132 of the mold 130. Optionally, each differentparticulate mineral mix is dispensed from a separate conveyor line(refer to FIGS. 2-3) that transports the respective mix to a regionabove the upwardly facing opening 132 so that the respective mix is thenvertically poured into the mold 130. Each conveyor line may transportthe respective mix according to a predefined pattern so that thedifferent particular mixes pour into the mold a predetermined series ofsuccessive layers, some or all of which can form the veins 51, 52, 53,54, 55 of the slab 50. Optionally, each of the successive layer of thedifferent particulate mineral mixes can be dispensed in differentamounts, thereby providing differently sized and positioned veins orstriations. Furthermore, each individual layer may be differently sizedat one end of the mold 130 compared to the other end of the mold 130,thereby further enhancing the complex striations and veining patterns inthe hardened slab 50 so as to increasingly emulate a quarried stone slab(e.g., a traditional quarried granite slab or the like).

In this embodiment, the slab 50 comprises four different particulatemineral mixes that are separately conveyed and dispensed into theupwardly facing opening 132 of the vertically oriented mold 130. Thedifferent mixes can be compaction molded and cured in the mold(described in more detail below) so as to provide the hardened slab 50(FIG. 1B) of composite stone material. One or more of the mixes that areused to form the composite stone material can include organic polymer(s)and inorganic (mineral) particulate component. The inorganic (mineral)particulate component may include such components as silicon, basalt,glass, diamond, rocks, pebbles, shells, a variety of quartz containingmaterials, such as, for example, but not limited to: crushed quartz,sand, quartz particles, and the like, or any combination thereof. Inthis embodiment, all four different particulate mineral mixes eachcomprise a quartz material as a predominant component, which may includesand of various particle sizes and of different combinations. In thehardened slab 50 (FIG. 1B), the organic and inorganic materials can belinked using a binder, which may include for example, mono-functional ormultifunctional silane molecules, dendrimeric molecules, and the like,that may have the ability to bind the organic and inorganic componentsof the composite stone mix. The binders may further include a mixture ofvarious components, such as initiators, hardeners, catalysators, bindingmolecules and bridges, or any combination thereof. Some or all of themixes dispensed in the mold 130 (FIG. 1A) may include components thatare combined in a mixing apparatus (not shown in FIG. 1A) prior to beingconveyed to the mold 130. The mixing apparatus can be used to blend rawmaterial (such as the quartz material, organic polymers, unsaturatedpolymers, and the like) at various ratios. For example, some or all ofthe mixes dispensed in the mold 130 may include about 8-95% quartzaggregates to about 5-15% polymer resins. In addition, various additivesmay be added to the raw materials in the mixing apparatus, suchadditives may include metallic pieces (e.g., copper flecks or the like),colorants, dyes, pigments, chemical reagents, antimicrobial substances,fungicidal agents, and the like, or any combination thereof. Inalternative embodiments, some or all of the quantity of quartzaggregates (mentioned above) can be replaced with or include porcelainand/or ceramic aggregate material.

Still referring to FIGS. 1A-B and 2, the mold 130 can be verticallyoriented during dispensation of the mineral particular mixes in that amajor surface of the mold is positioned in a vertical position or agenerally vertical position (e.g., 90 degrees from the horizontal +/−10degrees). In such circumstances, each mineral particulate mix isvertically poured into the mold and rests on a previously depositedlayer of a mineral particular mix (with the first layer being depositedinstead on a closed bottom edge of the vertically oriented mold 130).Preferably, the mold 130 at least partially defines a length L and awidth W of the hardened slab 50 (because the mold 130 retains theparticulate mineral mixes therein throughout the subsequent compactionand curing processes). In some embodiments, the width W of the slab 50formed in the mold 130 is at least 2 feet, between about 3 feet and 5feet, and preferably about 4.5 feet, and the length L of the slab 50formed in the mold 130 is at least 6 feet, and between about 6 feet and15 feet, preferably about 10 feet. Thus, for example, the slab 50 mayhave a width W of 4.5 feet and a length L of 10. Alternatively, the slab50 may have a width W of 26 inches and a length L of 10. Other slabsizes described in the above-mentioned ranges are also contemplatedherein. As such, even though each slab 50 can be quite large in lengthL, some or all of the veins 51, 52, 53, and 54 can nevertheless extendacross the full length of the slab 50. Additionally, some of the veins51, 52, 53, and 54 that do not extend across the full length of the slab50, at least some of those veins can optionally extend substantiallyacross the full length of the slab 50 so that a person viewing the slabinitially visualizes separated portions of the vein as being connectedform a full-length vein during an initial view. Optionally, during thevertical dispensation of the mineral particular mixes into the mold 130,the mold 130 may have a thickness T₁ at its lower edge that is differentfrom the thickness T₂ at its upper opening 132. For example, thethickness T₂ may be about twice the thickness T₁. The differentthicknesses T₁ and T₂ may be used to account for the additionalcompaction of the particulate mineral mixes that occurs near the loweredge of the slab as additional layers of the particulate mineral mixesare deposited into the mold 130. After the mold 130 is rotated to ahorizontal orientation for subsequent compaction and curing of the slab50, the mixture is more evenly compacted together and the mold 130defines a generally continuous thickness T (FIG. 1B) of the slab 50. Insome embodiments, the thickness T of the slab 50 formed in the mold 130is at least 0.2 cm, between about 0.2 cm and 5 cm, and preferably about3 cm. Each mold 130 may be formed of structure that comprises a flexiblepolymer (including an elastomeric material), paper, wood, metal or acombination thereof.

Referring now to FIG. 2, in some embodiments, a system 100 for forming aset of synthetic molded slab products (e.g., the slab 50 in FIG. 1B, theslab 600 in FIG. 7, or the like) is configured to vertically pourdifferently pigmented particulate mineral mixes into a verticallyoriented mold, which is then shifted to a horizontally oriented positionfor a subsequent compression molding operation (e.g., vibro-compactionmolding, curing, etc.). The system 100 in the depicted embodimentincludes an input conveyor 110 and an output conveyor 120. A collectionof slab molds 130 are transported on the input conveyor 110. The slabmolds 130 provide a form for synthetic molded slab products that are atleast three feet wide and at least six feet long, and about 4.5 feetwide by about 10 feet long in some embodiments depicted herein. Theinput conveyor 110 transports the slab molds 130 to a mold positioningtable 140, which is configured to help operators move and/or orient theslab molds 130.

In this embodiment, the slab molds 130 are moved horizontally (e.g.,relative to gravity) onto an apparatus 150 for pivoting each mold 130between a vertical orientation and a horizontal orientation. Theapparatus 150 in this embodiment serves as a tip table 150, which isconfigured to accept one or more of the slab molds 130, secure it, andpivot the slab mold 130 from the horizontal orientation to the verticalorientation (described above) with an open edge (numeral 132 in FIG. 1A)positioned at the top of the slab mold 130 when in the verticalorientation. For example, in this embodiment, the tip table 150 isconfigured to receive and releasably retain one mold 130 at a time.Additional details of this particular embodiment of the tip table 150are described further in connection with FIGS. 4A-6C. In alternativeembodiments, the tip table 150 can be configured to receive andreleasably retain multiple molds 130 at a time.

Still referring to FIG. 2, in this embodiment, the mold 130 verticallyoriented in the apparatus 150 is configured to receive four differentlypigmented mineral mixes (comprising mostly a quartz material asdescribed above), which can be conveyed from four corresponding mixersand directed to inputs 160 such as dispenser heads or other materialtransport structures. In this embodiment, each dispenser head 160 isconfigured to release a different particulate mineral mix (e.g.,different pigments, different mineral compositions, different additives,or a combination thereof) compared to the other dispenser heads 160.Each dispenser head 160 is configured to controllably dispense itssupply of corresponding particulate mineral mix for input into thevertically oriented mold 130 retained by the tip table 150. For example,the dispensing heads 160 are each configured with a shutter or valveapparatus (not shown) that is controllable to regulate the flow ofparticulate mineral mix from the dispensing head 160 for input to themold 130. In such embodiments, the dispensing heads (or other inputs fordistributing the particulate mineral mixes to the mold 130) can becontrolled according to a predetermined control algorithm so as todefine successive layers of the differently pigmented particulatemineral mixes for vertical dispensation into the slab mold 130 retainedby the tip table 150.

When the tipping table 150 retains a mold 130 in the verticalorientation, the upwardly facing opening 132 (FIG. 1A) of the mold 130is positioned below (e.g., relative to gravity) the outputs of themineral aggregate distributors 160. As such, the particulate mineralmixes that are dispensed from the outputs of the distributors 160 andthen through the upwardly facing opening 132 (FIG. 1A) of the mold 130.As such, the distributors 160 (each carrying a different particulatemineral mix according to a pattern dispensed by its correspondingdispensing head) can be used to pour the respective mix into thevertically oriented mold 130 to provide a predetermined series ofsuccessive layers (which are repeatable for each mold 130 in the line).As previously described, some or all of these successive layers ofdifferent particulate mineral mixes can form the lengthwise veins of thehardened slab (e.g., the slab 50 in FIG. 1B, the slab 600 in FIG. 7, orthe like).

In the illustrated example, four mineral aggregate inputs 160 are used,although in other examples, the slab may be formed from between 1 and 20different particulate mineral mixes, and more preferably between 3 and 8different particulate mineral mixes (which, in some embodiments, wouldprovide a system that would include a corresponding number of inputs160). In some examples, the number of mineral aggregate distributors 160can correspond equally to the number of differently pigmentedparticulate mineral mixes used to create the hardened slab product.

After the slab mold 130 retained by the tipping table 150 has beensufficiently filled (while in the vertically oriented orientation), thetip table 150 pivots or otherwise adjusts the slab mold 130 to ahorizontal orientation. The slab mold 130 (now a filled mold 180) ismoved out of the tip table 150, on a cushion of air provided by anothermold positioning table 170, to an output conveyor 120. As shown in FIG.2, the successive layers of different particulate mineral mixes thatwere vertically dispensed into the mold 130 are generally noticeable inthe filled molds 180 are arranged in the horizontal orientation on theoutput conveyer 120. Some or all of these successive layers of differentparticulate mineral mixes can form the lengthwise veins of the hardenedslab (e.g., the slab 50 in FIG. 1B, the slab 600 in FIG. 7, or thelike).

Optionally, the system 100 may be configured to provide one moregenerally “widthwise” or transverse veins 192 (as compared to thegenerally “lengthwise” veins 51, 52, 53, and 54 (FIG. 1B) defined by thesuccessive layers of different particulate mineral mixes previouslypoured into the mold 130 while at the tip table 150). Optionally, thesewidthwise veins 192 may be thinner and spread further apart than thegenerally “lengthwise” veins defined by the successive layers ofdifferent particulate mineral mixes. Also, these widthwise veins 192 maybe formed from a material having a different pigmentation than theparticulate mineral mixes dispensed from the inputs 160. For example,the system can be configured to controllably dispense the particulatemineral mix for the widthwise veins 192 in a selected location orpattern for each mold before the mold is advanced to a top moldattachment operation 194 or a vibro-compaction press 195 (FIG. 2),thereby providing a predetermined pattern of the widthwise veins 192that is repeatable for each of the filled molds. In some optionalcircumstances, the widthwise veins 192 may not extend through the fullthickness of the hardened slab (which can be different from some or allof the generally lengthwise veins 51, 52, 53, and 54 (FIG. 1B)).

Still referring to FIG. 2, the output conveyor 120 can be configured totransport each of the filled molds 180 to one or more sequent stationsin the system 100 for forming the hardened slab. For example, each ofthe filled molds 180 can continue to a subsequent station in which a topmold attachment 194 is positioned over the filled mold 180 so as toencase the layers of particular mineral mixes between the mold 130 and atop cover mold piece (not shown in FIG. 2). From there, the filled mold180 (now including the top cover mold piece continues to a subsequentstation in which a vibro-compaction press 195 applies compactionpressure, vibration, and vacuum to the contents inside the filled mold180, thereby converting the particulate mixes into a rigid slab. Afterthe vibro-compaction operation, the filled mold 180 (with the compactedand hardened slab therein) proceeds to a curing station 196 in which thematerial used to form the slab (including any resin binder material) arecured via a heating process or other curing process, thereby furtherstrengthening the slab inside the filled mold 180. After the slab isfully cured (and, optionally, after the slab is cooled), the primarymold 130 and the top mold cover piece are removed from the hardened andcured slab at a mold removal station 197. The primary mold 130 is thenreturned to the input conveyor 110 (FIG. 2). Then, in some embodiments,the hardened and cured slab is moved to a polisher station 198, in whicha major surface of the slab is polished to a smooth finish, thereby anappearance of the complex striations and veining patterns that emulate aquarried stone slab. Alternatively, the polisher station 198 is notimplemented so that the resulting slab has a more textured major surfacerather than a smooth, polished surface. In some embodiments of thesystem 100, the polished or otherwise exposed major surface of each ofthe synthetic molded slabs can provide an outer appearance that issubstantially repeatable for the other slabs (from the other filledmolds 180 in FIG. 2).

Referring now to FIG. 3, another example system 200 for forming asynthetic molded slab product can be configured to contemporaneouslyfill multiple vertically oriented molds 130, thereby increasing theproduction rate in some circumstances. The system 200 is substantiallysimilar in layout and operation to the system 100 (FIG. 2), having theinput conveyor 110, the output conveyor 120, the mold positioning tables140 and 170, the slab molds 130, and the filled molds 180. The system200, however, includes eight of the mineral aggregate inputs 160, withfour inputs 160 arranged to feed four different particulate mineralmixes into a first vertically oriented mold 130 secured to the tip table150, and another set of four inputs 160 arranged to feed the fourdifferent particulate mineral mixes into a second vertically orientedmold 130 secured to a second tip table 150 (not visible in FIG. 3).

Accordingly, the operation of the system 200 is substantially similar tothat of the system 100 (FIG. 2), except that multiple molds 130 aresubstantially vertically oriented and contemporaneously filled beforebeing adjusted to horizontal orientations and moved to the outputconveyor 120 as filled molds 180. As shown in FIG. 3, the filled molds180 that were simultaneously filled (in this embodiment, using the twoadjacent tip tables 150) can have substantially the same appearance ofveins defined by the successive layers of different particulate mineralmixes poured into each of the molds according to a predeterminedpattern.

Referring now to FIGS. 4A and 4B, each tip table 150 in the system 100or 200 can be configured to receive the mold 130 in a horizontalorientation. The tip table 150 is located vertically below a fill chute301, with respect to gravity. In the systems 100 and 200 (FIGS. 2 and 3,respectively), the chute 301 is positioned vertically below the gap(s)166 at the end of the belts 164, e.g., to direct fill from the mineralaggregate distributor 160 into the slab mold 130. The tip table 150includes a collection of supports 302 and a table base 304 connected bya pivot point 306 a and a pivot point 306 b (not visible). The supports302 provide support to elevate the table base 302 above a floor, and thepivot points 306 a-306 b provide a bearing upon which the table base 302can tilt relative to the supports 302.

As previously described, the mold positioning table 308 provides amechanism (e.g., rollers, conveyors, actuator arms, etc.) to move theslab mold into the tip table 150 between the table base 302 and a topplate 310 (e.g., while the tip table is in a horizontal configuration).Optionally, a film 320 extends across the surface of the top plate 310,between the top plate 310 and the slab mold 130. The film 320 is fedfrom a feeder roll 322 and is collected by a takeup roll 324. In use,the optional film provides a protective barrier between the top plate310 and filler material deposited into the mold (e.g., to maintain thecleanliness of the top plate 310 during repeated use with a series ofmolds 130). Predetermined lengths of the film 320 can be used once permold filling operation, or for multiple mold filling operations beforebeing advanced to the takeup roll 324 and a fresh length of the film 320is provided from the feeder roll 322. A collection of actuators 350controllably position the top plate 310 apart from the table base 302and the slab mold 130.

FIG. 5 is another cross-sectional view of the tip table 150 of FIGS.1-3B. In the illustrated view, the slab mold 130 is positioned in ahorizontal orientation within the tip table 150. The collection ofactuators 350 are actuated to bring a mold gasket 402 into contact withthe outer periphery of the slab mold 130. The collection of actuators350 are actuated to move the top plate 310 toward the slab mold 130,compressing the mold gasket 402 between the slab mold 130 and the topplate 310. Optionally, the combination of the mold gasket 402 and theslab mold 130 includes a slight asymmetry in the form of a trapezoidalcuboid (e.g., refer to T₁ and T₂ described in connection with FIG. 1A).In the configuration shown in FIG. 4, the slab mold provides three edgesand a one major face of a six-sided trapezoidal cuboid form, and thefilm 320 and the top plate 310 form another major face. An open end 410of the slab mold 130 forms the sixth side (e.g., the fourth edge) of thetrapezoidal cuboid form. In this embodiment, the major faces areoriented at a slight angle so as to be non-coplanar, with the cuboidhaving a relatively greater thickness (T₂ from FIG. 1A) along theopenable end 410 and a thickness (T₁ from FIG. 1A) along the opposingedge that is less than the thickness along the openable end 410. Withthe tip table 150 in the configuration shown in FIG. 5, the slab mold130 is ready to be repositioned to a vertical orientation for filling.

Referring now to FIGS. 6A-6C, the tip table 150 of FIGS. 1-5 can adjustthe slab mold 130 to the vertical orientation by pivoting about pivotpoints 306 a-b. In particular, the slab mold 130 is oriented to thevertical position by pivoting the table base 304, the mold positioningtable 308, the top plate 310, the mold gasket 402, and the film 320, onthe pivot points 306 a-306 b relative to the supports 302. As shown inFIG. 6B, in the illustrated example, the slab mold 130 is partly filledwith successive layers of different particulate mineral mixes 502 (e.g.,partially through the mold filling process; refer also to FIG. 1A foranother example). As discussed in the descriptions of FIGS. 2 and 3, thedifferent particulate mineral mixes are controllably released via theinputs 160s and poured (under the force of gravity in this embodiment)into the chute 301, through the open end 410, and into the slab mold130. The different particulate mineral mixes 502 includes multiple,variously designed and selected mixes (including predominantly a quartzmaterial in this embodiment) vertically poured into the mold 130 insuccessive layers, which can create different vein layers 506 a-506 b.As previously described in connection with FIGS. 1A and 1B, some or allof the vein layers 506 a-506 b can extend substantially from edge toedge and across the length L of the slab mold 130.

As discussed previously, the slab mold 130 in this embodiment provides atrapezoidal cuboid form. In the illustrated vertical orientation, theasymmetry of the slab mold 130 occurs from top to bottom, forming a veryslight “V” shape (e.g., refer also to the description of T₁ and T₂described in connection with FIG. 1A). In some embodiments, theasymmetry can be selected to at least partly offset the effects ofgravity on the slight compaction of the different particulate mineralmixes 502 at the lower edge of the mold 130 as the mixes fill the slabmold 130. Optionally, a vibrator 530 vibrates and/or shakes the slabmold 130 and the particulate mineral mixes 502 to promote a completefilling of the mold 130. Once the slab mold 130 is sufficiently filledwith the particulate mineral mixes 502 according to the predefinedpattern from the distributors 160 (FIGS. 2 and 3), the slab mold 130becomes the filled mold 180 (refer to FIGS. 2 and 3).

Referring now to FIG. 6C, an enlarged view of the chute 301 and the openend 410 (refer also to the upwardly facing opening 132 in FIG. 1A) ofthe slab mold 130. In this embodiment, the open end 410 includes a moldend cap 520, and the mold end cap 520 is movable about a pivot point 522to selectably open and close the openable end 410. When the slab mold130 is sufficiently filled with the filler 502, the mold end cap 520 ispivoted to the closed position to provide the sixth side of the cuboidform (e.g., to close the open edge of the filled mold. The tip table 150then adjusts the filled mold from the vertical orientation (FIGS. 6A-6C)to the horizontal orientation (refer to FIGS. 4A-5). The actuators 350can be activated to release the filled mold 180 from the tip table 150,and the filled mold 180 can be moved out of the tip table 150 and ontothe output conveyor 120 (FIGS. 2 and 3).

Referring now to FIG. 7, an example synthetic molded slab product 600can be formed by either of the systems of FIGS. 2 and 3 using acombination of differently pigmented particulate mineral mixes that arevertically poured according to predefined pattern into the mold 130. Insome embodiments, the synthetic molded slab product 600 can provide aveined appearance that emulates quarried stone slabs such as granite ormarble, depending upon the predefined dispensation pattern of thedifferent particular mixes. For example, the major surface 612 of theslab 600 can be polished and provide at least some veins 602, 606, and608 that extend fully across a complete length of the hardened slab 600(which may be about 6 feet to about 14 feet long, and preferably about10 feet long in this embodiment). Other veins 605 and 609 may extendonly partially across the length of the slab 50, and some veins 605 havemuch smaller size (although perhaps a much darker hue). Not only cansuch differently pigmented veins (602, 605, and 605, for example) extendacross the full length of the slab product, but such veins can alsoextend through the thickness 610 of the slab 600 from the first majorface 612 to the opposing major face 614 (thereby providing a naturalvein appearance even when the slab is cut and edged to specific shapesin living or working spaces (e.g., along a countertop, table, floor, orthe like). Additionally, at least the major surface 612 of the slab 600may include a plurality of veins 607 that are oriented in a transversedirection relative to the veins 602, 605, 606, 608 and 609. Such veinsmay be defined, for example, by the secondary dispenser 190 (refer toFIGS. 2 and 3). Some of these “widthwise” veins 607 can extend fullyacross a complete width of the hardened slab 600 (which may be about 2feet and about 6 feet wide, and preferably about 4.5 feet wide in thisembodiment). Because each slab 600 in the set of separately molded slabs(refer, for example, to the system in FIGS. 2 and 3) can include thelayers of different particulate mineral mixes dispensed vertically intothe mold 130 according to the predefined and repeatable dispensationpattern, multiple slabs 600 in the set can have similarly positionedveins in the major surface and can provide substantially the sameappearance to one another.

The synthetic molded slab 600 can be cut, milled, machined, or otherwiseprocessed to various shapes and sized (e.g., to provide custom-fitcountertop surfaces with optional holes for sinks, faucets, or otheramenities). For example, a section 630 is cut away from the syntheticmolded slab product 600. With the veins 602 and 605 extending into theinterior 606 and/or across the thickness 610, cutting and/or processingof the synthetic molded slab product 600 shows the veins 602, 605, 606,608 and 609 in a manner that emulates the aesthetics of quarried stoneslabs.

FIG. 8 is a flow diagram of an example process 700 for forming asynthetic molded slab product (such as slab 50 or 600 described above).In some implementations, the systems 100 or 200 of FIGS. 2 and 3 can beused to perform the process 700. The process 700 may include theoperation 710 of positioning a slab mold in a non-horizontalorientation, such as a substantially vertical orientation or anotherorientation that extends transverse to the horizontal. In such anoperation, a major face of the mold (which will define a major face ofthe slab product) can be positioned in a substantially vertical position(about 90 degrees from the horizontal +/−30 degrees (preferably +/−10degrees)), for example, by a tip table or another mold adjustmentapparatus. In some embodiments depicted above herein, the major face ofthe mold (which will define a major face of the slab product) can bepositioned in a vertically oriented position (about 90 degrees from thehorizontal +/−10 degrees) by the tip table 150 (FIGS. 2 and 3). Theprocess 700 may also include the operation 720 of dispensing multipledifferent particulate mineral mixes into the vertically oriented mold.For example, as previously described, differently pigmented mixescomprising predominantly a quartz material (e.g., a mix including theparticulate quartz material, one or more pigments, and one or more resinbonders) can be fed into a vertical pour operation using one of thedistributors 160 (FIGS. 2 and 3). Next, the process 700 may include theoperation 730 of adjusting the mold to a horizontal orientation whilethe different particulate mineral mixes are positioned in the mold.Again, such an operation can be performed, for example, by the tip table150 (FIGS. 2 and 3) or another mold adjustment apparatus. The process700 may further include the operation 740 of contemporaneously vibratingand compacting the particulate mineral mixes arranged in the mold whilethe mold is in the horizontal orientation. In such circumstances, theoperation 740 may provide a compacted slab of composite stone material.Also, in some embodiments, the process 700 may further include theoperation 750 of curing the compacted slab. The process 700 may alsoinclude the operation 760 of polishing a major surface of the slab toprovide a veined appearance on the polished surface of the slab,including but not limited to the examples described above.

Although a number of implementations have been described in detailabove, other modifications are possible. For example, the logic flowsdepicted in the figures do not require the particular order shown, orsequential order, to achieve desirable results. In addition, other stepsmay be provided, or steps may be eliminated, from the described flows,and other components may be added to, or removed from, the describedsystems. Accordingly, other implementations are within the scope of thefollowing claims.

1. A system for forming a synthetic molded slab using a combination ofdifferent particulate mineral mixes, comprising: a mold adjustmentapparatus configured to reposition a slab mold defining a mold spacethat is at least 6 feet long by at least 2 feet wide from asubstantially vertical orientation to a substantially horizontalorientation; one or more mineral aggregate distributors that are eachconfigured to dispense a corresponding particulate mineral mixvertically into the slab mold retained by the mold adjustment apparatus.2. The system of claim 1, wherein said one or more mineral aggregatedistributors include dispensing heads configured to distribute at leastfirst, second, third, and fourth differently pigmented particulatemineral mixes, wherein the dispensing heads output the at least first,second, third, and fourth differently pigmented particulate mineralmixes according to a predetermined control algorithm so as to definesuccessive layers of the differently pigmented particulate mineral mixesfor vertical dispensation into the slab mold retained by the moldadjustment apparatus.
 3. The system of claim 1, wherein said one or moremineral aggregate distributors include dispensing heads configured todistribute at least first, second, and third differently pigmentedparticulate mineral mixes, wherein the dispensing heads output the atleast first, second, and third differently pigmented particulate mineralmixes according to a predetermined control algorithm so as to definesuccessive layers of the differently pigmented particulate mineral mixesfor vertical dispensation into the slab mold retained by the moldadjustment apparatus.
 4. The system of claim 1, wherein said one or moremineral aggregate distributors include dispensing heads configured todistribute at least first and second differently pigmented particulatemineral mixes, wherein the dispensing heads output the at least firstand second differently pigmented particulate mineral mixes according toa predetermined control algorithm so as to define successive layers ofthe first and second pigmented particulate mineral mixes for verticaldispensation into the slab mold retained by the mold adjustmentapparatus.
 5. The system of claim 4, wherein the predetermined controlalgorithm is configured such that the first particulate mineral mix isseparated from and forms a substantially unmixed layer with respect tothe second particulate mineral mix.
 6. The system of claim 1, wherein atleast one of the mineral aggregate distributors is configured todispense the corresponding particulate mineral mix vertically into theslab mold retained by the mold adjustment apparatus such that theparticulate mineral mix defines a first pigmented vein extendinggenerally lengthwise across the full length of the slab mold.
 7. Thesystem of claim 1, comprising one or more mixing apparatuses configuredto combine components of the particulate mineral mixes, each particulatemineral mix comprising a quartz material and at least one binder.
 8. Thesystem of claim 1, comprising a vibro-compactor configured to vibrateand compact the particulate mineral mixes arranged in the slab moldwhile the slab mold is in a substantially horizontal orientation.
 9. Thesystem of claim 1, comprising a curing station configured to cure theparticulate mineral mixes while the slab mold is in a substantiallyhorizontal orientation.
 10. The system of claim 1, wherein the one ormore mineral aggregate distributors are configured to dispense acorresponding particulate mineral mix vertically into an open end of theslab mold retained by the mold adjustment apparatus in a verticalorientation.
 11. The system of claim 10, wherein the end of the slabmold comprises a mold end cap movable to open and close the edge of theslab mold.
 12. The system of claim 1, comprising one or more actuatorsconfigured to compress a mold gasket between a top plate and the slabmold.
 13. The system of claim 1, wherein the slab mold in a verticalorientation defines a mold space having a first edge thickness that issmaller than and parallel to a second edge thickness proximate to anupwardly facing open edge of the slab mold.
 14. A system for forming asynthetic molded slab using a combination of different particulatemineral mixes, comprising: a mold adjustment apparatus configured toreposition a slab mold defining a mold space that is at least 6 feetlong by at least 2 feet wide from a substantially vertical orientationto a substantially horizontal orientation; and one or more mineralaggregate distributors including one or more dispensing heads configuredto distribute at least first and second differently pigmentedparticulate mineral mixes vertically into the slab mold retained by themold adjustment apparatus in a vertical orientation; wherein thedispensing heads output the at least first and second differentlypigmented particulate mineral mixes according to a predetermined controlalgorithm such that the first particulate mineral mix is separated fromand forms a substantially unmixed layer with respect to the secondparticulate mineral mix.
 15. The system of claim 14, wherein said one ormore mineral aggregate distributors include dispensing heads configuredto distribute third and fourth differently pigmented particulate mineralmixes, wherein the dispensing heads output the third and fourthdifferently pigmented particulate mineral mixes according to apredetermined control algorithm so as to define successive layers of thethird and fourth particulate mineral mixes for vertical dispensationinto the slab mold retained by the mold adjustment apparatus.
 16. Thesystem of claim 14, comprising one or more mixing apparatuses configuredto combine components of the particulate mineral mixes, each particulatemineral mix comprising a quartz material and at least one binder. 17.The system of claim 14, wherein at least one of the mineral aggregatedistributors is configured to dispense the first pigmented particulatemineral mix vertically into the slab mold retained by the moldadjustment apparatus such that the first pigmented particulate mineralmix defines a first pigmented vein extending generally lengthwise acrossthe full length of the slab mold.
 18. The system of claim 14, comprisinga vibro-compactor configured to vibrate and compact the particulatemineral mixes arranged in the slab mold while the slab mold is in asubstantially horizontal orientation.
 19. The system of claim 14,wherein the one or more mineral aggregate distributors are configured todispense a corresponding particulate mineral mix vertically into an openend of the slab mold retained by the mold adjustment apparatus in avertical orientation.
 20. The system of claim 19, wherein the end of theslab mold comprises a mold end cap movable to open and close the edge ofthe slab mold.